US 12,296,571 B2
In-line lamination process for producing thermoplastic composite panels with embossed film layers
Liqing Wei, Forest, VA (US)
Assigned to Hanwha Azdel, Inc., Forest, VA (US)
Filed by Liqing Wei, Forest, VA (US)
Filed on May 12, 2022, as Appl. No. 17/743,269.
Application 17/743,269 is a continuation in part of application No. 17/525,469, filed on Nov. 12, 2021.
Claims priority of provisional application 63/188,358, filed on May 13, 2021.
Claims priority of provisional application 63/145,073, filed on Feb. 3, 2021.
Claims priority of provisional application 63/112,914, filed on Nov. 12, 2020.
Prior Publication US 2022/0379591 A1, Dec. 1, 2022
Int. Cl. B32B 37/02 (2006.01); B32B 5/10 (2006.01); B32B 7/12 (2006.01); B32B 27/12 (2006.01); B32B 27/32 (2006.01); B32B 37/06 (2006.01); B32B 38/06 (2006.01); B32B 39/00 (2006.01); B32B 38/16 (2006.01)
CPC B32B 37/02 (2013.01) [B32B 5/10 (2013.01); B32B 7/12 (2013.01); B32B 27/12 (2013.01); B32B 27/322 (2013.01); B32B 37/06 (2013.01); B32B 38/06 (2013.01); B32B 39/00 (2013.01); B32B 2038/166 (2013.01); B32B 2250/03 (2013.01); B32B 2260/021 (2013.01); B32B 2260/046 (2013.01); B32B 2305/026 (2013.01); B32B 2305/08 (2013.01); B32B 2307/102 (2013.01); B32B 2307/3065 (2013.01); B32B 2307/538 (2013.01); B32B 2307/54 (2013.01); B32B 2307/706 (2013.01); B32B 2307/732 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An in-line process of producing a thermoplastic composite article using an in-line system, the in-line process comprising:
combining reinforcing materials and a thermoplastic material with an aqueous solution;
disposing the aqueous solution, the reinforcing materials and the thermoplastic material which have been combined onto a moving support;
removing water from the disposed aqueous solution on the moving support to form a web comprising open cell structures formed from the reinforcing materials and the thermoplastic material;
drying the web on the moving support to provide a dried, porous core layer;
heating the dried, porous core layer on the moving support to melt the thermoplastic material of the dried, porous core layer to provide a heated, porous core layer;
disposing a first embossed film layer on a first surface of the heated, porous core layer on the moving support; and
applying pressure to the heated, porous core layer comprising the disposed first embossed film layer on the moving support to provide a thermoplastic composite article and retain embossing of the embossed film layer on the thermoplastic composite article.